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ZAPI AC3-AC4 Manual PDF
ZAPI AC3-AC4 Manual PDF
EQUIPMENTS CONSTRUCTION
Via Parma, 59 42028 POVIGLIO (RE) ITALY
Tel +39 0522 960050 Fax +39 0522 960259
e-mail: zapi@zapispa.it web: www.zapispa.it
EN
User Manual
AC-3 FLASH
AC-4 FLASH
INVERTER
The contents of this publication is a ZAPI S.p.A. property; all related authorizations are covered
by Copyright. Any partial or total reproduction is prohibited.
Under no circumstances will Zapi S.p.A. be held responsible to third parties for damage caused
by the improper use of the present publication and of the device/devices described in it.
Zapi spa reserves the right to make changes or improvements to its products at any time and
without notice.
The present publication reflects the characteristics of the product described at the moment of
distribution. The publication therefore does not reflect any changes in the characteristics of the
product as a result of updating.
NOTES LEGEND
4
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Contents
1
2
5
6
INTRODUCTION ...................................................................................................................6
SPECIFICATION ...................................................................................................................7
2.1
AC-3 FLASH technical specifications .........................................................................7
2.2
AC-4 FLASH technical specifications .........................................................................7
2.3
Block diagram .............................................................................................................8
SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT.......9
3.1
Main contactor ............................................................................................................9
3.2
Microswitches .............................................................................................................9
3.3
Accelerator unit...........................................................................................................9
3.4
Other analog control devices ....................................................................................10
3.5
Speed feedback........................................................................................................11
INSTALLATION HINTS.......................................................................................................12
4.1
Wires and fuses ........................................................................................................12
4.1.1
Connection cables ......................................................................................12
4.1.2
Fuse for I/O circuits.....................................................................................12
4.1.3
Fuse for power section................................................................................12
4.2
Installation of the hardware.......................................................................................13
4.2.1
Positioning and cooling of the controller .....................................................13
4.2.2
Connection of power cables........................................................................13
4.2.3
CAN connections and possible interferences .............................................14
4.2.4
I/O connections ...........................................................................................16
4.2.5
Connection of the encoder..........................................................................16
4.2.6
Main contactor and key connection ............................................................17
4.2.7
Insulation of truck frame..............................................................................18
4.3
Hardware protection and safety features..................................................................18
4.3.1
Protection features......................................................................................18
4.3.2
Safety Features...........................................................................................19
4.4
EMC..........................................................................................................................20
4.5
Various suggestions .................................................................................................21
OPERATIONAL FEATURES ..............................................................................................22
5.1
Diagnosis ..................................................................................................................22
DESCRIPTION OF CONNECTORS....................................................................................24
6.1
Connectors of the logic - Traction configuration .......................................................24
6.1.1
Ampseal and Molex Spox connectors.........................................................24
6.1.2
Amp Saab 42 poles connector....................................................................26
6.1.3
Molex Minifit connectors .............................................................................28
6.2
Connectors of the logic - Pump configuration...........................................................30
6.2.1
Ampseal and Molex Spox connectors.........................................................30
6.2.2
Amp Saab 42 poles connector....................................................................31
6.2.3
Molex Minifit connectors .............................................................................34
6.3
Description of power connections.............................................................................36
DRAWINGS .........................................................................................................................37
7.1
AC-3 FLASH mechanical drawing ............................................................................37
7.2
AC-4 FLASH mechanical drawing ............................................................................38
7.3
Connection drawing - Traction configuration ............................................................39
7.3.1
Ampseal and Molex Spox connectors.........................................................39
7.3.2
Amp Saab 42 poles connector....................................................................40
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7.3.3
Molex Minifit connectors ............................................................................. 41
Connection drawing - Pump configuration................................................................ 42
7.4.1
Ampseal and Molex Spox connectors ........................................................ 42
7.4.2
Amp Saab 42 poles connector ................................................................... 43
7.4.3
Molex Minifit connectors ............................................................................. 44
7.5
Connection drawing - Combi configuration............................................................... 45
7.5.1
Ampseal and Molex Spox connectors ........................................................ 45
7.5.2
Amp Saab 42 poles connector ................................................................... 46
7.5.3
Molex Minifit connectors ............................................................................. 47
8
PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE .................................. 48
8.1
Adjustments via Console .......................................................................................... 48
8.2
Additional programming tools ................................................................................... 48
8.3
Description of Console & Connection....................................................................... 49
8.4
Description of Standard Console Menu.................................................................... 49
8.4.1
Traction configuration ................................................................................. 50
8.4.2
Pump configuration..................................................................................... 51
8.5
Sequence for setting up the parameters .................................................................. 52
8.5.1
Traction....................................................................................................... 52
8.5.2
Pump .......................................................................................................... 52
8.6
OPTION and ADJUSTMENTS configuration............................................................ 53
8.6.1
Traction....................................................................................................... 53
8.6.2
Pump .......................................................................................................... 57
8.7
PARAMETER configuration...................................................................................... 64
8.7.1
Traction....................................................................................................... 64
8.7.2
Pump .......................................................................................................... 65
8.8
TESTER: description of the functions....................................................................... 68
8.8.1
Traction....................................................................................................... 68
8.8.2
Pump .......................................................................................................... 69
9
OTHER FUNCTIONS .......................................................................................................... 72
9.1
Description of Console SAVE function................................................................... 72
9.2
Description of Console RESTORE function. .......................................................... 73
9.3
Description of ALARMS menu ............................................................................... 74
9.4
Description of Console PROGRAM VACC function............................................... 75
10 AC-3 / AC-4 FLASH DIAGNOSTIC ALARM DESCRIPTION.......................................... 77
10.1 Analysis of alarms for Traction controller ................................................................. 77
10.2 Analysis of alarms for Pump controller ..................................................................... 83
11 RECOMMENDED SPARE PARTS FOR INVERTER ......................................................... 88
12 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......................... 89
7.4
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APPROVAL SIGNS
COMPANY FUNCTION
INITIALS
SIGN
PROJECT MANAGER
TECHNICAL ELECTRONIC
MANAGER VISA
SALES MANAGER VISA
Publication N: ADWZP0DF
Edition: May 2011
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1 INTRODUCTION
Within the ZAPIMOS family, the AC-3 FLASH and the AC-4 FLASH inverters are
the model suitable for control of 922 kW motors;. they have been expressly
designed for battery electric traction.
Their typical applications are:
electric truck
electric cars
tractors
buses.
The are available for battery voltages from 24V to 120V.
Both AC3 FLASH and AC4 FLASH can be purchased with three different I/O
connectors:
Ampseal 35 poles (plus a Molex Spox connector for the Zapi console)
Amp Saab 42 poles
Molex Minifit
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2 SPECIFICATION
2.1 AC-3 FLASH technical specifications
Inverter for AC asynchronous 3-phase motors
Regenerative braking functions
Can-bus interface
Flash memory (256 Kbytes On-Chip Program Memory)
Digital control based upon a microcontroller
Voltage ..................................................................... 36/48 V; 72/80 V; 96 V; 120 V
Maximum current (36/48 V)........................................................ 600 A (RMS) for 3'
Maximum current (72/80 V)........................................................ 600 A (RMS) for 3'
Maximum current (96 V).............................................................450 A (RMS) for 3
Maximum current (120 V)...........................................................500 A (RMS) for 3
Operating frequency....................................................................................... 8 kHz
External temperature range ............................................................. -30 C 40 C
Maximum inverter temperature (at full power) ................................................75 C
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The use of special devices to be connected to the inverter, has to discussed with
Zapi Technicians
3.2 Microswitches
-
The microswitches must have a contact resistance lower than 0.1 ohm and a
leakage current lower than 100 A.
When full load connected, the voltage drop between the key switch contacts
must be lower than 0.1 V.
The microswitches send a voltage signal to the microprocessor when a
function request (for ex.: forward request) is made.
Microswitches are used to send digital signals and thus are typically
connected to digital inputs.
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Potentiometer value should be in the 0.5 10 kohm range; generally, the load
should be in the 1.5 mA to 30 mA range. Faults can occur if it is outside this
range.
The Procedure for automatic potentiometer signal acquisition is carried out using
the Console. This enables adjustment of the minimum and maximum useful
signal level (PROGRAM VACC function, see Chapter 9.4), in either direction.
This function is unique when it is necessary to compensate for asymmetry with
the mechanical elements associated with the potentiometer, especially relating to
the minimum level. The sequence of procedure is described in the programming
console manual.
The two graphs show the output voltage from a non-calibrated potentiometer with
respect to the mechanical zero of the control lever. MI and MA indicate the point
where the direction switches close. 0 represents the mechanical zero of the
rotation.
The Left Hand graph shows the relationship of the motor voltage without signal
acquisition being made. The Right Hand Graph shows the same relationship after
signal acquisition of the potentiometer.
Note: The encoder resolution and the motor poles pair (the controller can
handle), is specified in the home page display of the handset showing following
headline:
AC3T2D
F
ZP1.13
That means:
AC3T = AC-3 traction controller (AC3P = AC-3 pump controller)
2 = motors poles pair number
D = 128 pulses/rev encoder
F = flash
The encoder resolution is given by the last letter in the following list:
A = 32 pulses/rev
B = 64 pulses/rev
C = 80 pulses/rev
D = 128 pulses/rev
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4 INSTALLATION HINTS
In the description of these installation suggestions you will find some boxes of
different colours, they mean:
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Notice that the purpose of the power fuse is not to protect the power section of
the inverter. In case of an internal short circuit a damage in the inverter will occur
too quickly and the fuse will not blow. The purpose of the fuse is to protect the
Before doing any operation, ensure that the battery is disconnected and
when all the installation is completed start the machine with the drive
wheels raised from the floor to ensure that any installation error do not
compromise safety.
After operation, even with the Key Switch open, the internal capacitors may
remain charged for some time. For safe operation, we recommend that the
battery is disconnected, and a short circuit is made between Battery
Positive and Battery Negative power terminals of the inverter using a
Resistor between 10 ohm and 100 ohm.
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may cause power section failure. A lower voltage may prevent the logic
operating.
CAN stands for Controller Area Network. It is a communication protocol for real
time control applications. CAN operates at data rate of up to 1 Megabits per
second.
It was invented by the German company Bosch to be used in the car industry to
permit communication among the various electronic modules of a vehicle,
connected as illustrated in this image:
The best cable for can connections is the twisted pair; if it is necessary to
increase the immunity of the system to disturbances, a good choice would be
to use a cable with a shield connected to the frame of the truck. Sometimes it
is sufficient a simple double wire cable or a duplex cable not shielded.
In a system like an industrial truck, where power cables carry hundreds of
Ampere, there are voltage drops due to the impedance of the cables, and
that could cause errors on the data transmitted through the can wires. In the
following figures there is an overview of wrong and right layouts of the cables
routing.
Wrong Layout:
R
Can Bus
Power cables
Module
1
Module
2
Module
3
R
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Correct Layout:
R
Can Bus
Power cables
Module
1
Module
2
Module
3
R
The chain starts from the BATT post of the controller that works with the highest
current, and the others are connected in a decreasing order of power.
Otherwise, if two controllers are similar in power (for example a traction and a
pump motor controller) and a third module works with less current, the best way
to deal this configuration is to create a common ground point (star configuration).
Correct Layout:
R
Can Bus
Power cables
Module
1
Module
2
Center of the Ground connection
Module
3
R
In this case the power cables starting from the two similar controllers must be as
short as possible. Of course also the diameter of the cable concurs in the voltage
ADWZP0DF - AC3 FLASH / AC4 FLASH INVERTER - User Manual
Page - 15/89
drops described before (higher diameter means lower impedance), so in this last
example the cable between the minus of the Battery and the common ground
point (pointed by the arrow in the image) must be dimensioned taking into
account thermal and voltage drop problems.
Can advantages
The complexity of today systems needs more and more data, signal and
information must flow from a node to another. CAN is the solution to different
problems that arise from this complexity
- simplified design (readily available, multi sourced components and tools)
- lower costs (less and smaller cables )
- improved reliability (fewer connections)
- analysis of problems improved (easy connection with a pc to read the data
flowing through the cable).
After crimping the cable, verify that all strands are entrapped in the wire
barrel.
Verify that all the crimped contacts are completely inserted on the connector
cavities.
A cable connected to the wrong pin can lead to short circuits and failure;
so, before turning on the truck for the first time, verify with a multimeter the
continuity between the starting point and the end of a signal wire.
For information about the mating connector pin assignment see the chapter
description of the connectors.
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Ampseal
Amp Saab
Minifit
A1
A29
E1
+5 V/+12 V
A2
A30
E2
GND
negative of encoder
power supply.
A13
A31
E3
phase A of encoder.
A22
A18
E4
A*
A14
A32
E5
phase B of encoder.
A23
A19
E6
B*
4) Connection of encoder with open collector output: +12 V power supply (Minifit
connectors).
VERY IMPORTANT
It is necessary to specify to Zapi, when ordering the controller, the type of
encoder used: power supply, electronic output and n of pulses for
revolution. This is necessary because the logic unit must be set in the
correct way by Zapi.
The connection of the main contactor can be carried out following the
drawing in the figure.
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4.4 EMC
EMC stands for Electromagnetic Compatibility, and it represents the studies and
the tests on the electromagnetic energy generated or received by an electrical
device.
So the analysis works in two directions:
1) The study of the emission problems, the disturbances generated by the
device and the possible countermeasure to prevent the propagation of that
energy; we talk about conduction issues when guiding structures such as
wires and cables are involved, radiated emissions issues when it is studied
the propagation of electromagnetic energy through the open space. In our
case the origin of the disturbances can be found inside the controller with the
switching of the mosfets which are working at high frequency and generate
RF energy, but wires and cables have the key role to propagate the
disturbs because they works as antennas, so a good layout of the cables
and their shielding can solve the majority of the emission problems.
2) The study of the immunity can be divided in two main branches: protection
from electromagnetic fields and from electrostatic discharge.
The electromagnetic immunity concern the susceptibility of the controller
with regard to electromagnetic fields and their influence on the correct work
made by the electronic device.
There are well defined tests which the machine has to be exposed to.
These tests are carried out at determined levels of electromagnetic fields, to
simulate external undesired disturbances and verify the electronic devices
response.
3) The second type of immunity, ESD, concerns the prevention of the effects of
electric current due to excessive electric charge stored in an object. In fact,
when a charge is created on a material and it remains there, it becomes an
electrostatic charge; ESD happens when there is a rapid transfer from a
charged object to another. This rapid transfer has, in turn, two important
effects:
A) this rapid charge transfer can determine, by induction, disturbs on the
signal wiring and thus create malfunctions; this effect is particularly
critical in modern machines, with serial communications (canbus)
which are spread everywhere on the truck and which carry critical
information.
B) in the worst case and when the amount of charge is very high, the
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5 OPERATIONAL FEATURES
-
Speed control.
Optimum behaviour an a slope due to the speed feedback:
- the motor speed follows the accelerator, starting a regenerative braking if
the speed overtakes the speed set-point.
- the system can perform an electrical stop on a ramp (the machine is
electrically hold on a slope) for a programmable time (see also chapter
8.6).
Stable speed in every position of the accelerator.
Regenerative release braking based upon deceleration ramps.
Regenerative braking when the accelerator pedal is partially released
(deceleration).
Direction inversion with regenerative braking based upon deceleration ramp.
Regenerative braking and direction inversion without contactors: only the
main contactor is present.
The release braking ramp can be modulated by an analog input, so that a
proportional brake feature is obtained.
Optimum sensitivity at low speeds.
Voltage boost at the start and with overload to obtain more torque (with
current control).
The inverter can drive an electromechanical brake.
Hydraulic steering function:
1) traction inverter
- the traction inverter sends a "hydraulic steering function" request to
the pump inverter on the can-bus line (see also Chapter 8.6).
- moreover, if the pump inverter is not present (for ex: tractor
application), the traction inverter can manage an "hydraulic steering
function" by driving a hydro contactor which drive a hydraulic steering
motor (A28 Ampseal, A9 Amp Saab 42 poles, B9 Minifit) output, see
also Chapter 8.6).
2) pump inverter
- the pump inverter manage an "hydraulic steering function". That is, it
drives the pump motor at the programmed speed for the
programmed time.
High efficiency of motor and battery due to high frequency commutations.
Self diagnosis.
Modification of parameters through the programming console.
Internal hour-meter with values that can be displayed on the console.
Memory of the last five alarms with relative hour-meter and temperature
displayed on the console.
Test function within console for checking main parameters.
5.1 Diagnosis
The microcontroller continually monitors the inverter and carries out a diagnostic
procedure on the main functions. The diagnosis is different in the four main
operational modes:
1) Diagnosis at start-up: watchdog circuit, current sensor, capacitor charging,
phase's voltages, contactor drives, can-bus interface. It also checks if the
switch sequence for operation is correct and if the output of accelerator unit
is correct.
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6 DESCRIPTION OF CONNECTORS
6.1 Connectors of the logic - Traction configuration
The AC-3 / AC-4 FLASH has been designed to be produced with three different
types of I/O connector: an AMPSEAL 35 poles connector plus a MOLEX SPOX 8
poles connector (used to connect the Console), one AMP SAAB 42 poles
connector or six Molex Minifit connectors.
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A1
+12V (+5V)
A2
ENC GND
A3
PPOT
A4
SEAT
A5
FORWARD
A6
BACKWARD
A7
A8
PB
A9
SR/HB
A10
A11
A12
SAFETY
A13
ENC A
Phase A of encoder.
A14
ENC B
Phase B of encoder.
A15
NPOT
A16
CPOT
A17
CAN T
A18
CAN H
A19
CAN L
A20
NPOTB
It is a ground reference.
A21
CPOTB
A22
ENC A*
A23
ENC B*
A24
NTHERM
It is a ground reference.
A25
PTHERM
A26
NMC
A27
PMC
A28
NBRAKE
A29
PBRAKE
A30
CM
A31
MODE
A32
PPOTB
A33
KEY
A34
-BATT
It is a ground reference.
A35
-BATT
It is a ground reference.
B1
PCLRXD
B2
NCLRXD
B3
PCLTXD
B4
NCLTXD
B5
GND
B6
+12
B7
FLASH
B8
FLASH
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A1
PPOT
A2
NPOTB
It is a ground reference.
A3
PPOTB
A4
MOT TH.
A5
NTHERM
It is a ground reference.
A6
-BATT
It is a ground reference.
A7
NMC
A8
PMC
A9
NBRAKE
A10
PBRAKE
A11
CM
A12
KEY
A13
SAFETY
A14
-BATT
It is a ground reference.
A15
CPOT
A16
NPOT
A17
CPOTB
A18
ENC A*
A19
ENC B*
A20
MODE
A21
FORWARD
A22
BACKWARD
A23
PB
A25
A26
A27
SEAT
A28
SR/HB
A29
+12V (+5V)
A30
ENC GND
A31
ENC A
Phase A of encoder.
A32
ENC B
Phase B of encoder.
A33
CANT
A34
CANL
A35
CANH
A36
PCLRXD
A37
NCLRXD
A38
PCLTXD
A39
NCLTXD
A40
GND
A41
+12
A42
FLASH
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A1
CPOT
A2
PPOT
A3
NPOT
A4
CM
A5
FORW
A6
BW
A7
PB
A8
CPOTB
A9
PPOTB
A10
NPOTB
It is a ground reference.
A11
-BATT
It is a ground reference.
A12
BACK. FORW
A13
BACK. BACK
A14
B1
KEY
B2
PMC
B3
PBRAKE
B4
SEAT
B5
SAFETY
B6
PTHERM
B7
CM
B8
NMC
B9
NBRAKE
B10
SR/HB
B11
GND
It is a ground reference.
B12
NTHERM
It is a ground reference.
C1
CAN-L
C2
CAN-L-OUT
C3
CAN-H
C4
CAN-H-OUT
D1
-BATT
It is a ground reference.
D2
MODE
E1E6
F1
PCLRXD
F2
NCLRXD
F3
PCLTXD
F4
NCLTXD
F5
GND
F6
+12
F7
FLASH
F8
FLASH
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A1
+12V (+5V)
A2
ENC GND
A3
PPOT
A4
4 TH
A5
LIFT ENABLE
A6
1 ST
A7
DIG IN
A8
3 RD
A9
2 ND
A10
HYDRO.
A11
SR.
A12
SAFETY
A13
ENC A
Phase A of encoder.
A14
ENC B
Phase B of encoder.
A15
NPOT
A16
CPOT
A17
CAN T
A18
CAN H
A19
CAN L
A20
NPOT-AUX
It is a ground reference.
A21
CPOT-AUX
A22
ENC A*
A23
ENC B*
output).
A24
NTHERM
It is a ground reference.
A25
PTHERM
A26
NAUX
A27
PAUX
A28
NHYDRO
A29
PHYDRO
A30
CM
A31
MODE
A32
PPOT-AUX
A33
KEY
A34
-BATT
It is a ground reference.
A35
-BATT
It is a ground reference.
B1
PCLRXD
B2
NCLRXD
B3
PCLTXD
B4
NCLTXD
B5
GND
B6
+12
B7
FLASH
B8
FLASH
PPOT
A2
NPOT-AUX
It is a ground reference.
A3
PPOT-AUX
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A4
PTHERM
A5
NTHERM
It is a ground reference.
A6
-BATT
It is a ground reference.
A7
NAUX
A8
PAUX
A9
NHYDRO
A10
PHYDRO
A11
CM
A12
KEY
A13
SAFETY
A14
-BATT
It is a ground reference.
A15
CPOT
A16
NPOT
A17
CPOT-AUX
A18
ENC A*
A19
ENC B*
A20
MODE
A21
LIFT ENABLE
A22
1 ST
A23
3 RD
A24
HYDRO.
A25
SR.
A26
DIG IN
A27
4 TH
A28
2 ND
A29
+12V (+5V)
A30
ENC GND
A31
ENC A
Phase A of encoder.
A32
ENC B
Phase B of encoder.
A33
CANT
A34
CANL
A35
CANH
A36
PCLRXD
A37
NCLRXD
A38
PCLTXD
A39
NCLTXD
A40
GND
A41
+12
A42
FLASH
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A1
CPOT
A2
PPOT
A3
NPOT
A4
CM
A5
LIFT ENABLE
A6
1 ST
A7
3 RD
A8
CPOT-AUX
A9
PPOT-AUX
A10
NPOTB
It is a ground reference.
A11
-BATT
It is a ground reference.
A12
HYDRO.
A13
SR.
A14
DIG IN
B1
KEY
B2
PAUX
B3
PHYDRO
B4
4 TH
B5
SAFETY
B6
PTHERM
B7
CM
Common of 2 ND / 4 TH microswitches.
B8
NAUX
B9
NHYDRO
2 ND
B11
GND
It is a ground reference.
B12
NTHERM
It is a ground reference.
C1
CAN-L
C2
CAN-L-OUT
C3
CAN-H
C4
CAN-H-OUT
D1
-BATT
It is a ground reference.
D2
MODE
E1E6
F1
PCLRXD
F2
NCLRXD
F3
PCLTXD
F4
NCLTXD
F5
GND
F6
+12
F7
FLASH
F8
FLASH
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-BATT
+BATT
U; V; W
7 DRAWINGS
7.1 AC-3 FLASH mechanical drawing
BATT
BATT
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If interested in one of these solutions, please contact Zapi for further information
Special software versions may have additional parameters and setting. In this
case additional documentation will be provided.
Page - 49/89
Page - 50/89
Page - 51/89
8.5.1 Traction
1) Select the Options required, See Chapter 8.6. In particular:
- Select and set the Battery voltage.
- Select the type of motor temperature sensor.
2) Confirm correct installation of all wires. Use the Consoles TESTER (Chapter
8.8) to assist.
3) Perform the accelerator signal acquisition procedure using the Console
PROGRAM VACC. Procedure is detailed on Chapter 9.4.
4) Set the "MAXIMUM CURRENT Current, using the table on Chapter 8.7.
5) Set the Acceleration Delay requirements for the machine. Test the
parameters in both directions.
6) Set the FREQUENCY CREEP level starting from level 0.6 Hz. The machine
should just move when the accelerator microswitch is closed. Increase the
Level accordingly.
7) Set the Speed Reductions as required. Make adjustments to CUTBACK
SPEED parameter. Check the performance with the accelerator pedal totally
depressed. If the machine is a forklift, check the performance with and
without load.
8) RELEASE BRAKING. Operate the machine at full speed. Release the
accelerator pedal. Adjust the level to your requirements. If the machine is a
forklift, check the performance with and without load.
9) INVERSION BRAKING. Operate the machine at 25% full speed. Whilst
travelling INVERT the Direction Switch. Set a soft Level of Inversion Braking.
When satisfactory, operate the machine at Full Speed and repeat. If the
machine is a Forklift, repeat the tests and make adjustments with and without
load. The unloaded full speed condition should be the most representative
condition.
10) PEDAL BRAKING (If used). Operate the machine at full Speed. Release the
accelerator pedal and press the Pedal Brake. Set braking level to your
requirements.
11) Set MAX SPEED FORW.
12) Set MAX SPEED BACK (Reverse).
13) Make the choice for the truck behaviour on a slope (see chapter 8.4). If the
"Stop on ramp" option is ON, set the desired value of "auxiliary time"
parameter.
8.5.2 Pump
1) Select the Options required, See Chapter 8.6. In particular:
- Select and set the Battery voltage.
- Select the type of motor temperature sensor
2) Confirm correct installation of all wires. Use the Consoles TESTER (Chapter
Page - 52/89
8.8) to assist.
3) Perform the lift signal acquisition procedure using the Console PROGRAM
VACC. Procedure is detailed on Chapter 9.4.
4) Set the "MAXIMUM CURRENT Current, using the table in Chapter 8.7.
5) Set the Acceleration and Deceleration Delay requirements for the pump.
6) Set the MIN SPEED UP level starting from 0 Hz. The pump should just turn
when the request microswitch is closed. Increase the level accordingly.
7) Set the Speed Reductions as required. Make adjustments to CUTBACK
SPEED. Check the performance with the full request. Check the
performance with and without load.
8) Set MAX SPEED UP (max speed of pump motor).
9) Set HYD SPEED FINE to adjust the hydraulic steering speed (pump motor
speed when HYDRO function is requested).
10) Set AUXILIARY TIME (time delay before pump stops when an hydraulic
steering function request is switched off).
Page - 53/89
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SUBMENU "ADJUSTMENTS"
1) SET POT BRK MIN
It records the minimum value of braking pedal potentiometer when the
braking pedal switch is closed; the procedure is similar to the "Program Vacc"
function (see chapter 9.4). This procedure must be carried out only if the
"Pedal braking" option is programmed as "Analog".
2) SET POT BRK MAX
It records the maximum value of braking pedal potentiometer when the
braking pedal is fully pressed; the procedure is similar to the "Program Vacc"
function (see chapter 9.4). This procedure must be carried out only if the
"Pedal braking" option is programmed as "Analog".
3) SET BATTERY TYPE
It selects the nominal battery voltage.
4) ADJUST BATTERY
Fine adjustment of the battery voltage measured by the controller.
5) THROTTLE 0 ZONE
It establishes a deadband in the accelerator input curve (see also curve
below).
6) THROTTLE X POINT
This parameter changes the characteristic of the accelerator input curve.
7) THROTTLE Y POINT
This parameter changes the characteristic of the accelerator input curve.
VACC MIN and VACC MAX are values programmable by the "Program Vacc"
function.
8) ADJUSTMENT #04
This parameter determines the motor temperature level at which the Motor
temperature alarm is signalled. The range is from 70 C to 160 C with 10 C
steps. This parameter must be adjusted only if the Set temperature (menu
Set option) parameter is programmed Analog.
9) ADJUSTMENT #03
This parameter isn't used.
10) ADJUSTMENT #02
It adjusts the lower level of the battery discharge table.
11) ADJUSTMENT #01
It adjusts the upper level of the battery discharge table.
Page - 55/89
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BRAKE
BRAKE
HYDRO
CONT.
STOP
ON
RAMP
A9 (Amp Saab)
B9 (Minifit), A28 (Ampseal)
OUTPUT
ON
OFF
ON
HYDRO
CONT.
OFF
EXCL.
HYDRO
ON
EXCL.
HYDRO
OFF
BEHAVIOUR ON A SLOPE
The truck is electrically hold on a
slope; when the time set by
"auxiliary time" parameter is
elapsed the brake is applied and
the 3-phase bridge is released.
Do not use this combination if
the negative brake is not
installed.
The truck is not electrically hold
on a slope, but comes down
very slowly; when the time set
by "auxiliary time" parameter is
elapsed, the brake is applied
and the 3-phase bridge is
opened. Do not use this
combination if the negative
brake is not installed.
The truck is electrically hold on a
slope; when the time set by
"auxiliary time" parameter is
elapsed, the truck comes down
very slowly, till the flat is
reached.
The truck is not electrically hold
on a slope, but comes down
very slowly till the flat is
reached.
The truck is electrically hold on a
slope; when the time set by
"auxiliary time" parameter is
elapsed, the truck comes down
very slowly, till the flat is
reached.
The truck is not electrically hold
on a slope, but comes down
very slowly till the flat is
reached.
8.6.2 Pump
Using the CONFIG MENU of the programming console, the user can configure
the following functions.
SUBMENU "SET OPTIONS"
1) HOUR COUNTER
- RUNNING: the counter registers travel time only.
- KEY ON: the counter registers when the "key" switch is closed.
2) BATTERY CHECK
- ON: the battery discharge level check is carried out; when the battery
level reaches 10%, an alarm is signalled and the maximum current is
reduced to the half of the programmed value.
- OFF: the battery discharge level check is carried out but no alarm is
signalled.
ADWZP0DF - AC3 FLASH / AC4 FLASH INVERTER - User Manual
Page - 57/89
Very important:
In the combi system (pump + traction), the battery discharge calculation for
the complete system is carried out by the traction inverter; the information
about the pump inverter consumption is sent on the can-bus line from the
pump inverter to the traction inverter. So the correct programming for the
"Battery check" option is:
traction inverter: ON
pump inverter: OFF.
3) SET TEMPERATURE
- DIGITAL: a digital (ON/OFF) motor thermal sensor is connected
between B6 and B12 (Minifit), A4 and A5 (Amp Saab 42 poles), A24 and
A25 (Ampseal).
- ANALOG: an analog motor thermal sensor (like a KTY-84) is connected
between B6 and B12 (Minifit), A4 and A5 (Amp Saab 42 poles), A24 and
A25 (Ampseal).
- NONE:
no motor thermal sensor switch is connected.
VACC MIN and VACC MAX are values programmable by the "Program
Page - 58/89
Vacc" function.
6) ADJUSTMENT #04
This parameter determines the motor temperature level at which the Motor
temperature alarm is signalled. The range is from 70 C to 160 C with 10 C
steps. This parameter must be adjusted only if the Set temperature (menu
Set option) parameter is programmed Analog.
7) ADJUSTMENT #03
This parameter isnt used.
8) ADJUSTMENT #02
It adjusts the lower level of the battery discharge table.
9) ADJUSTMENT #01
It adjusts the upper level of the battery discharge table.
Page - 59/89
% ' %
' ' '
CONFIG MENU
SET MODEL
% ' '
' ' '
CONFIG MENU
SET OPTIONS
' % '
' ' '
HOUR COUNTER
RUNNING
% ' '
% ' '
BATTERY CHECK
OFF
' ' %
' ' %
BATTERY CHECK
ON
' ' '
' % '
' % '
' ' '
Page - 60/89
CONFIG MENU
SET OPTIONS
' ' '
' % '
' % '
' ' '
BATTERY TYPE
48V
% ' '
% ' '
TROTTLE 0 ZONE
3%
' ' %
' ' %
TROTTLE 0 ZONE
7%
' % '
' ' '
Page - 61/89
Flow chart showing how to use the SET BATTERY TYPE adjustment
AC3 ZAPI V0.0
80V 550A 00000
% ' %
' ' '
CONFIG MENU
SET MODEL
% ' '
' ' '
CONFIG MENU
ADJUSTMENTS
' % '
' ' '
' ' %
' ' '
' % '
' ' '
Page - 62/89
% ' %
' ' '
CONFIG MENU
SET MODEL
% ' '
' ' '
CONFIG MENU
ADJUSTMENTS
' % '
' ' '
% ' '
% ' '
ADJUSTMENT BATTERY
82.1V
' ' %
' ' %
ADJUSTMENT BATTERY
84.5V
' ' '
' % '
' % '
' ' '
CONFIG MENU
ADJUSTMENTS
' ' '
' % '
Page - 63/89
8.7.1 Traction
The following parameters can be modified:
1) ACCELERATION DELAY
It determines the acceleration ramp. The parameter value (in seconds) sets
the time needed to speed up the motor from 0 to 100Hz.
2) RELEASE BRAKING
It controls the deceleration ramp when the travel request is released. The
parameter value (in seconds) sets the time needed to slow down the motor
from 100 to 0Hz.
3) INVERS. BRAKING
It controls the deceleration ramp when the direction switch is inverted during
travel. The parameter value (in seconds) sets the time needed to slow down
the motor from 100 to 0Hz.
4) PEDAL BRAKING
It determines the deceleration ramp when the travel request is released and
the brake pedal switch is closed. The parameter value (in seconds) sets the
time needed to slow down the motor from 100 to 0Hz.
5) SPEED LIMIT BRK.
Deceleration ramp when the pedal position is changed but not completely
released. The parameter value (in seconds) sets the time needed to slow
down the motor from 100 to 0Hz.
6) BRAKE CUTBACK
It determines the deceleration ramp when the speed reduction input becomes
active and the motor slow down. The parameter value (in seconds) sets the
time needed to slow down the motor from 100 to 0Hz.
7) MAX SPEED FORW
It determines the maximum speed in forward direction.
8) MAX SPEED BACK
It determines the maximum speed in backward direction.
9) CUTBACK SPEED
Speed reduction (percentage of the max speed) when the cutback switch is
active.
10) CURVE CUTBACK
Determines the speed reduction (percentage of the max speed) during a
steering movement and only if an electric steering control, like a Zapi EPS, is
present in the truck.
11) FREQUENCY CREEP
Minimum speed (in Hz) when the forward or reverse switch is closed, but the
accelerator is at its minimum position.
12) MAXIMUM CURRENT
This parameter changes the maximum current of the inverter. It is a
percentage of the current defined by factory settings.
13) BACKING SPEED
It determines the speed while the inching function is active.
14) BACKING TIME
It determines the time duration of the inching function.
15) AUXILIARY TIME
During the time, defined by this option, the truck is hold on the ramp if the
Page - 64/89
PROGRAMMED LEVEL
UNIT
0
Sec.
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Sec.
8.9
8.3
7.7
7.1
6.6
6.0
5.5
4.9
4.4
3.8
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Hz
65
80
95
110
125
140
155
170
185
200
Hz
65
80
95
110
125
140
155
170
185
200
CUTBACK SPEED
%Max Sp
10
20
30
40
50
60
70
80
90
100
CURVE CUTBACK
%Max Sp
10
21
33
44
55
66
78
89
100
Hz
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
3.0
%IMAX
47
53
58
64
70
76
82
88
94
100
BACKING SPEED
Hz
10
12
14
16
18
BACKING TIME
Sec.
0. 2
0.5
1.0
1.4
1.8
2.3
2.7
3.1
3.6
4.0
AUXILIARY TIME
Sec.
1.5
2.0
2.5
3.0
3.5
4.0
4.5
FREQUENCY CREEP
MAXIMUM CURRENT
(*)
(**)
The acceleration time shown is the time from 0 Hz to 100 Hz. This is the
ideal ramp calculated by the software; the real ramp could change as a
function of motor control parameter setting and, obviously, as a function
of the load.
The braking feature is based upon deceleration ramps. The value shown
in the table is the time to decrease the speed from 100 Hz to 0 Hz. This
is the ideal ramps calculated by the software; the real ramp could
change as a function of motor control parameter setting and, obviously,
as a function of the load.
8.7.2 Pump
The following parameters can be modified:
1) ACCELER. DELAY
It determines the acceleration ramp. The parameter value (in seconds) sets
the time needed to speed up the motor from 0 to 100Hz.
2) DECELER. DELAY
It controls the deceleration ramp when the pump request is released. The
parameter value (in seconds) sets the time needed to slow down the motor
from 100 to 0Hz.
ADWZP0DF - AC3 FLASH / AC4 FLASH INVERTER - User Manual
Page - 65/89
3) MAX SPEED UP
It determines the maximum lifting speed with a potentiometer control.
4) MIN SPEED UP
It determines the minimum lifting speed with a potentiometer control when
the lifting enable switch is closed nut the lift potentiometer is at its minimum.
5) CUTBACK SPEED
Speed reduction (percentage of the max speed) when the cutback switch is
active.
6) 1ST SPEED FINE
Speed (in Hz) which is set when the First speed request is activated. It is
can be regulated with a 1Hz precision.
7) 2ND SPEED FINE
Speed (in Hz) which is set when the Second speed request is activated. It is
can be regulated with a 1Hz precision.
8) 3RD SPEED FINE
Speed (in Hz) which is set when the Third speed request is activated. It is
can be regulated with a 1Hz precision.
9) 4TH SPEED FINE
Speed (in Hz) which is set when the Fourth speed request is activated. It is
can be regulated with a 1Hz precision.
10) HYD SPEED FINE
Speed (in Hz) which is set when the hydraulic steering request is activated. It
is can be regulated with a 1Hz precision.
11) MAXIMUM CURRENT
This parameter changes the maximum current of the inverter. It is a
percentage of the current defined by factory settings.
12) AUXILIARY TIME
Time delay before switching off the hydraulic steering function after the
hydraulic steering request has been deativated.
The following table shows the different values at which the parameters can be
set.
PARAMETER
PROGRAMMED LEVEL
UNIT
0
Sec.
0.5
0.7
1.0
1.4
1.9
2.5
3.2
4.0
4.8
5.5
Sec.
0.5
0.7
1.0
1.4
1.9
2.5
3.2
4.0
4.8
5.5
MAX SPEED UP
Hz
65
80
95
110
125
140
155
170
185
200
MIN SPEED UP
Hz
25.5
%Max Sp
10
20
30
40
50
60
70
80
90
100
Hz
%IMAX
47
53
58
64
70
76
82
88
94
100
Sec.
0.2
0.4
0.8
1.0
1.5
2.0
3.0
4.0
5.0
CUTBACK SPEED
SPEED FINE (ALL) (***)
MAXIMUM CURRENT
AUXILIARY TIME
(*)
(**)
Page - 66/89
(***)
MAIN MENU
PARAMETER CHANGE
' % '
' ' '
ACCEL. DELAY
LEVEL = 4
% ' '
% ' '
RELEASE BRAKING
LEVEL = 5
' ' %
' ' %
RELEASE BRAKING
LEVEL = 6
' % '
' ' '
MAIN MENU
PARAMETER CHANGE
Page - 67/89
8.8.1 Traction
1) MOTOR VOLTAGE
This is the voltage supplied to the motor by the inverter; it is expressed as a
percentage of the full voltage (which depends of the battery voltage).
2) FREQUENCY
This is the frequency of the voltage and current supplied to the motor.
3) ENCODER
This is the speed of the motor, expressed in the same unit of the frequency;
this information comes from the speed sensor.
4) SLIP VALUE
This is the difference of speed between the rotating field and the shaft of the
motor, expressed in the same unit of the frequency.
5) CURRENT RMS
Root Mean Square value of the motor current.
6) TEMPERATURE
The temperature measured on the aluminium heat sink holding the MOSFET
devices.
7) MOTOR TEMPERAT.
This is the temperature of the motor; if the option is programmed "None" (see
chapter 8.6) it shows 0.
8) ACCELERATOR
The voltage of the accelerator potentiometer's wiper (CPOT). The voltage
level is shown on the Left Hand Side of the Console Display and the value in
percentage is shown on the Right Hand Side.
9) FORWARD SWITCH
The level of the Forward direction digital entry FW.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
10) BACKWARD SWITCH
The level of the Reverse direction digital entry BW.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
11) ENABLE SWITCH
Status of the accelerator enable input.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
12) SEAT SWITCH
The level of the Seat switch digital entry.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
13) BACKING F.
Status of the inching function (forward direction) input.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
14) BACKING B.
Status of the inching function (backward direction) input.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
Page - 68/89
8.8.2 Pump
1) MOTOR VOLTAGE
This is the voltage supplied to the motor by the inverter; it is expressed as a
percentage of the full voltage (which depends of the battery voltage).
2) FREQUENCY
This is the frequency of the voltage and current supplied to the motor.
3) ENCODER
This is the speed of the motor, expressed in the same unit of the frequency;
this information comes from the speed sensor.
4) SLIP VALUE
This is the difference of speed between the rotating field and the shaft of the
motor, expressed in the same unit of the frequency.
5) CURRENT RMS
Root Mean Square value of the motor current.
6) TEMPERATURE
The temperature measured on the aluminium heat sink holding the MOSFET
devices.
7) MOTOR TEMPERATURE
This is the temperature of the motor; if the option is programmed "None" (see
chapter 8.6) it shows 0.
8) ACCELERATOR
The voltage of the lift potentiometer's wiper (CPOT). The voltage level is
shown on the Left Hand Side of the Console Display and the value in
percentage is shown on the Right Hand Side.
9) LIFTING SWITCH
Status of the lifting switch.
- ON / +VB = active entry of closed switch.
- OFF / GND = non active entry of open switch.
ADWZP0DF - AC3 FLASH / AC4 FLASH INVERTER - User Manual
Page - 69/89
Page - 70/89
Flow Chart showing how to use the TESTER function of the Digital Console.
1) Opening Zapi Display.
2) Press ENTER to go into the General menu.
3) The Display will show:
4) Press ROLL UP or ROLL DOWN button until
TESTER MENU appear on the display.
5) The Display shows:
' % '
' ' '
MOTOR VOLTAGE
%
% ' '
% ' '
FREQUENCY
Hz
' ' '
' % '
MAIN MENU
TESTER
Remember it is not possible to make any changes using TESTER. All you can do
is measure as if you were using a pre-connected multimeter.
Page - 71/89
9 OTHER FUNCTIONS
9.1 Description of Console SAVE function
The SAVE function allows the operator to transmit the Parameter values and
Configuration data of the controller into the Console memory. It is possible to
load 16 different programmes.
The information saved in the Console memory can then be reloaded into another
inverter using the RESTORE function (Chapter 9.2).
The data that is available via the SAVE function is as follows:
- All Parameter Values (PARAMETER CHANGE).
- Options (SET OPTIONS).
- The Level of the Battery (ADJUST BATTERY).
Flow Chart showing how to use the SAVE function of the Digital Console.
1) Opening Zapi Display.
2) Press ENTER to go into the General menu.
3) The Display will show:
4) Press ROLL UP or ROLL DOWN button until
SAVE PARAM. appears on the display.
5) The Display will show:
6) Press ENTER to go into the SAVE function.
SELECT: MOD. 00
FREE
% ' '
% ' '
SELECT: MOD. 01
FREE
Page - 72/89
' % '
' ' '
READING
ACCEL. DELAY (ECC.)
MAIN MENU
SAVE PARAM
MAIN MENU
PARAMETER CHANGE
% ' '
% ' '
MAIN MENU
RESTORE PARAM.
' % '
' ' '
SELECT : MOD. 00
AC3 ZAPI V1
% ' '
% ' '
SELECT : MOD. 01
AC3 ZAPI V1
' % '
' ' '
' % '
' ' '
Page - 73/89
12) You can see the items that are being stored in
the inverter memory whilst the RESTORE routine is
happening.
STORING
ACCELER. DELAY
MAIN MENU
RESTORE PARAM.
Page - 74/89
CODE
CODE
CLEAR LOGBOOK?
YES=ENTER NO=OUT
' % '
' ' '
MAIN MENU
PARAMETER CHANGE
% ' '
% ' '
MAIN MENU
PROGRAM VACC
' % '
' ' '
VACC SETTING
4.8
4.8
' % '
' ' '
MIN
0.0
VACC
-
MAX
0.0
Page - 75/89
Page - 76/89
MIN
0.6
VACC
MAX
4.4
4
U
U
U
Notice that special software versions may have additional alarm codes. Please
ask Zapi for further information
3) LOGIC FAILURE #1
This alarm signals that an undervoltage / overvoltage protection operation
has occurred. This alarms stops the controller operation and opens the MC.
Two possible reasons:
A) A real undervoltage / overvoltage situation happened. The alarm should
disappear by simply switching off and on again the key. The cause of the
undervoltage/overvoltage event has to be found on the application. For
example: a very strong regenerative braking has increased too much the
ADWZP0DF - AC3 FLASH / AC4 FLASH INVERTER - User Manual
Page - 77/89
4)
5)
6)
7)
8)
9)
10)
Page - 78/89
battery voltage.
B) Fault in the hardware section of the logic board which manages the
hardware protection. The controller must be replaced.
The activation of this alarm is regulated by internal voltage thresholds, which
depend on the nominal battery voltage. The list of these thresholds is the
following
36V/48V: undervoltage 15V ; overvoltage 65V
80V: undervoltage 30V ; overvoltage 115V
96V: undervoltage 34V ; overvoltage 125V
120V: undervoltage 40V ; overvoltage 152V
LOGIC FAILURE #2
Fault in the hardware section of the logic board which reads the feedback
signals of the phase' s voltages. This alarms stops the controller operation
and opens the MC. The controller must be replaced.
LOGIC FAILURE #3
Fault in the hardware section of the logic board which manages the hardware
current protection. This alarms stops the controller operation and opens the
MC. The controller must be replaced.
CHECK UP NEEDED
This is a warning, not a real alarm. It is an information for the user that the
programmed time for maintenance is elapsed.
INCORRECT START
This alarm signals an incorrect starting sequence. Possible causes:
A) microswitch failure;
B) error in sequence made by the operator;
C) incorrect or defective wiring;
Check all external cables and devices controlling the starting sequence. In
case the failure persists, replace the controller.
FORW + BACK
An alarm is signalled when a double running request is made simultaneously:
both forward and backward directions are selected. Possible causes:
A) microswitch failure;
B) error in sequence made by the operator;
C) incorrect or defective wiring;
Check all external cables and devices controlling the selection of the travel
direction. In case the failure persists, replace the controller.
HANDBRAKE
The truck does not start because the handbrake switch is opened. Possible
causes:
A) microswitch failure
B) error in sequence made by the operator;
C) incorrect or defective wiring;
Check the handbrake cable and switches. In case the failure persists, replace
the controller.
ENCODER ERROR
Two consecutive readings of the encoder speed are too much different:
because of the inertia of the system it is not possible the encoder changes its
speed a lot in a short period. The alarm is set to appear if the read speed
changes of more than 40 Hz in few milliseconds.
This alarm stops the power bridge.
Possible causes:
- an encoder failure has occurred (e.g. one or two channels of the encoder
are corrupted or disconnected). Check both the electric and the
mechanical encoder functionality.
- the electromagnetic noise on the sensor bearing disturbs the encoder
ADWZP0DF - AC3 FLASH / AC4 FLASH INVERTER - User Manual
signal. This event is quite common at low speed and very high motor
currents when the bearing is not shielded.
- the truck has encountered an high step or a wide hole on the road. The
abnormal movement of the wheel may trigger this alarm.
11) CAPACITOR CHARGE
When the key is switched ON, the inverter tries to charge the internal
capacitor bank through a power resistance, and it checks if the capacitor are
charged within a timeout . The following image shows the circuit which
charges the capacitors:
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The gain acquisition test can be carried out only by Zapi personnel or other
trained technicians!
18) MAIN CONTACTOR ALARMS
The main contactor has many diagnoses related to it. Here there is the
complete list.
Notice that all of these alarm cause the opening of the MC and the stop of all
functions of the controller.
- DRIVER SHORTED
When the key is switched ON, the controller checks that the NMC pin is
not at zero voltage. If it is, this alarm is signalled, MC stay open and any
function is prevented.
Possible causes are :
o Driver inside the NMC circuit is shorted. The controller has to be
replaced.
o An external short is present between NMC and ground. Check
the cables.
- CONTACTOR DRIVER
When all initial diagnoses are finished, the traction logic tries to closes
the MC by activating the NMC driver (NMC voltage is pulled towards
Batt voltage). If the voltage at the NMC pin does not become low, this
alarm is signalled and any function is prevented.
This alarm is caused by an internal failure: the controller must be
replaced.
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19)
20)
21)
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24)
CONTACTOR OPEN
The main contactor coil has been driven by the logic board (NMC has
become low), but the contactor does not close. Any function is prevented.
Two possible reasons:
A) the MC coil is damaged or it is rated to a voltage larger than the
voltage applied. Check the coil.
B) the two contacts of the contactor are not properly working, and they
cannot close. Check them.
- CONTACTOR CLOSED
AT start-up the controller checks if the MC contact is already closed
when the coil isnt driven yet. The test is carried out by trying to discharge
the capacitor bank. If they dont discharge, the failure condition is entered
and any function is prevented.
It is suggested to check the contactor contacts, in particular if they are
mechanically stuck or pasted.
Notice that this test isnt carried out if, at start-up, the capacitor are
completely discharged.
AUX OUTPUT KO
The controller checks the driver inside the NEB pin. If the status of the driver
output does not correspond to the signal coming from the microcontroller, this
alarm is signalled, MC opens and all function are stopped.
Possible causes are:
o Presence of external shorts or misconnections. Check the EB coil
wire.
o There is an internal failure. Replace the controller.
COIL SHORTED
Inside the logic board there is a shunt in common with both the NMC and the
NEB output drivers. This shunt is used to detect overcurrent conditions in
these outputs: in case of an overcurrent event the NMC and ENB drivers are
stopped and this alarm is raised. Look for short circuit in parallel with the MC
and EB coils or if these coils have the correct impedance. If no short is
present and the alarm persists, the failure is internal to the controller, which
must be replaced.
The overcurrent detection circuit is checked at start-up too. If this test fails,
the alarm is raised. In this case, the failure is only internal to the logic board
and the controller must be replaced.
HIGH TEMPERATURE
This is a warning and not an alarm. It indicates that the controller
temperature is greater than 75 C. The maximum current is reduced
proportionally to the temperature increase. The controller current drops to
zero at 100 C.
If the alarm is signalled when the controller is cold there is an internal failure
and the controller must be replaced.
MOTOR TEMPERATURE
This warning is signalled if the motor temperature switch opens (digital
sensor) or if the analog signal overtakes the cut off level (defined by
ADJUSTMENT #4 parameter). The motor current is reduced to avoid any
damage to the motor. If it happens when the motor is cold, check the wiring.
If the wires are ok, replace the controller.
THERMIC SENSOR KO
The range of internal temperature sensor is always checked and a warning is
signalled if it is out of range. When this happens, the motor current is
reduced to half its max value.
This is an internal failure: replace the controller.
MOT. TH. SENSOR KO
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This test is performed if the thermal sensor is analog: the range of the sensor
is always checked and a warning is signalled if it is out of range.
When this happens, the motor current is reduced to half its max value..
Check the integrity of the sensor and of its connections. If the sensor is ok
and the alarm persists, the controller must be replaced.
CAN BUS KO
The diagnosis of the CAN-BUS line is present only if the inverter uses this
link (it depends on the software version). It is signalled when the inverter
does not receive any message from the CAN-BUS line.
Possible causes are:
o CAN wiring disconnected or damaged, check them.
o Failure inside the external module which has to send the messages
that the inverter is waiting. Check any module connected via
CANbus.
o There is a problem inside the logic board, replace the controller.
SAFETY
This alarm is signalled when the SAFETY input is open. The "SAFETY"
circuit gets active and opens (via hardware control) the drivers of MC and
EB. Moreover any function of the controller is stopped.
This could happen because:
o This pin is not connected to ground level (single controller
configuration). Check the wires.
o The slave module has deactivated the output which holds the
SAFETY input at low level (master-slave configuration). Check the
slave controller and the connection between master and slave.
o The SAFETY input circuit has an internal failure. Replace the
controller.
SAFETY KO
This alarm is present on some software version, when a slave controller (the
pump in combi configuration) uses one of its outputs to drive the SAFETY pin
at low level. At start-up the master controller tests if the SAFETY input is
not active while the slave controller has not yet activated its driver: in this
way the master can detect the presence of a short circuit between SAFETY
pin and ground.
This alarm arises if a short is detected: the MC does not close and any
function is prevented. Possible causes:
o The SAFETY pin has an external short: check the wires
o The output driver of the slave module is shorted: check the slave
controller and replace it if necessary
o The internal SAFETY circuit has a failure: replace the master
controller.
BATTERY LOW
If the BATTERY CHECK parameter is set ON, a battery discharge algorithm
is executed. When the estimated charge level is 10%, this alarm is signalled
and the current is reduced to the half of the programmed level.
WRONG SET BATT.
When the key is turned ON, the controller check the battery voltage and
verifies it is within a window around the nominal value. If not, the MC does
not close and any operation is prevented. Replace the battery with a correct
battery.
WAITING FOR NODE
This warning is present on some software version. The controller, via
CANbus, waits some synchronization signal from an external module before
performing a particular action, for example closing the MC. If this signal is not
received in time, the controller stays stuck in an idle state, showing this
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11)
12)
13)
14)
B)
the potentiometer is not correctly connected. Check the cables;
C)
the potentiometer itself is defective. Check the potentiometer.
PEDAL WIRE KO
The inverter continuously checks the NPOT pin to find out if the
potentiometer has been disconnected. Inside the NPOT circuit there is a
sense diode, which is on only if the potentiometer is correctly connected
between PPOT and NPOT. If the controller detects the diode turn-off, the
alarm is signalled because either PPOT or NPOT are not connected
anymore.
Controller operation is prevented while this alarm is active.
Check the potentiometer cables if this alarm arises.
If the alarm persists, there is an internal failure and the controller must be
replaced.
STBY I HIGH
Test carried out in stand-by. The controller checks if the current in stand-by is
zero. If it is non-zero, this alarm is activated. The controller opens the MC
and it inhibits machine operations.
Possible causes:
A) current sensor failure;
B) logic board failure.
In both cases the controller must be replaced.
SEAT KO
This alarm may be present in combi systems (traction + pump). The pump
can use one of its digital input to read the status of the SEAT switch together
with the traction controller. Then master and slaves compare the two read
status via CAN messages. The alarm is signalled if a mismatch is found.
Check the connection of the SEAT switch to both master and slave. If no
failure is found, the problem is internal to the controller.
DATA ACQUISITION
This alarm is signalled in the current gain acquisition phase. Wait the end of
the acquisition activity.
The gain acquisition test can be carried out only by Zapi personnel or other
trained technicians!
15) MAIN CONTACTOR ALARMS
In the combi system (pump + traction) the main contactor is driven by the
traction inverter. So the following description concerns the pump inverter
when used independently from the traction inverter. In this configuration the
pump inverter manages its own main contactor.
Notice that all of these alarm cause the opening of the MC and the stop of all
functions of the controller.
- DRIVER SHORTED
When the key is switched ON, the controller checks that the NMC pin is
not at zero voltage. If it is, this alarm is signalled, MC stay open and any
function is prevented.
Possible causes are :
Driver inside the NMC circuit is shorted. The controller has to be
replaced.
An external short is present between NMC and ground. Check
the cables.
- CONTACTOR DRIVER
When all initial diagnoses are finished, the traction logic tries to closes
the MC by activating the NMC driver (NMC voltage is pulled towards
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Batt voltage). If the voltage at the NMC pin does not become low, this
alarm is signalled and any function is prevented.
This alarm is caused by an internal failure: the controller must be
replaced.
- CONTACTOR OPEN
The main contactor coil has been driven by the logic board (NMC has
become low), but the contactor does not close. Any function is prevented.
Two possible reasons:
A)
the MC coil is damaged or it is rated to a voltage larger than the
voltage applied. Check the coil.
B)
the two contacts of the contactor are not properly working, and
they cannot close. Check them.
- CONTACTOR CLOSED
AT start-up the controller checks if the MC contact is already closed
when the coil isnt driven yet. The test is carried out by trying to discharge
the capacitor bank. If they dont discharge, the failure condition is entered
and any function is prevented.
It is suggested to check the contactor contacts, in particular if they are
mechanically stuck or pasted.
Notice that this test isnt carried out if, at start-up, the capacitor are
completely discharged.
AUX OUTPUT KO
The controller checks the driver inside the NEB pin. If the status of the driver
output does not correspond to the signal coming from the microcontroller,
this alarm is signalled, MC opens and all function are stopped.
Possible causes are:
Presence of external shorts or misconnections. Check the EB coil
wire.
There is an internal failure. Replace the controller.
COIL SHORTED
Inside the logic board there is a shunt in common with both the NMC and the
NEB output drivers. This shunt is used to detect overcurrent conditions in
these outputs: in case of an overcurrent event the NMC and ENB drivers are
stopped and this alarm is raised. Look for short circuit in parallel with the MC
and EB coils or if these coils have the correct impedance. If no short is
present and the alarm persists, the failure is internal to the controller, which
must be replaced.
The overcurrent detection circuit is checked at start-up too. If this test fails,
the alarm is raised. In this case, the failure is only internal to the logic board
and the controller must be replaced.
HIGH TEMPERATURE
This is a warning and not an alarm. It indicates that the controller
temperature is greater than 75 C. The maximum current is reduced
proportionally to the temperature increase. The controller current drops to
zero at 100 C.
If the alarm is signalled when the controller is cold there is an internal failure
and the controller must be replaced.
MOTOR TEMPERATURE
This warning is signalled if the motor temperature switch opens (digital
sensor) or if the analog signal overtakes the cut off level (defined by
ADJUSTMENT #4 parameter). The motor current is reduced to avoid any
damage to the motor. If it happens when the motor is cold, check the wiring.
If the wires are ok, replace the controller.
THERMIC SENSOR KO
The range of internal temperature sensor is always checked and a warning is
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Part number
Description
C16507
C16505
C16500
C16520
C29509
C29532
C12532
C12442
C12358
C12359
C12414
C12407
C12403
C12796
C12777
12 PERIODIC MAINTENANCE TO BE
REPEATED AT TIMES INDICATED
Check the wear and condition of the Contactors moving and fixed contacts.
Electrical Contacts should be checked every 3 months.
Check the Foot pedal or Tiller microswitch. Using a suitable test meter, confirm
that there is no electrical resistance between the contacts by measuring the volt
drop between the terminals. Switches should operate with a firm click sound.
Microswitches should be checked every 3 months.
Check the Battery cables, cables to the inverter, and cables to the motor. Ensure
the insulation is sound and the connections are tight.
Cables should be checked every 3 months.
Check the mechanical operation of the pedal or tiller. Are the return springs ok.
Do the potentiometers wind up to their full or programmed level.
Check every 3 months.
Check the mechanical operation of the Contactor(s). Moving contacts should be
free to move without restriction.
Check every 3 months.
Checks should be carried out by qualified personnel and any replacement parts
used should be original. Beware of NON ORIGINAL PARTS.
The installation of this electronic controller should be made according to the
diagrams included in this Manual. Any variations or special requirements should
be made after consulting a Zapi Agent. The supplier is not responsible for any
problem that arises from wiring methods that differ from information included in
this Manual.
During periodic checks, if a technician finds any situation that could cause
damage or compromise safety, the matter should be bought to the attention of a
Zapi Agent immediately. The Agent will then take the decision regarding
operational safety of the machine.
Remember that Battery Powered Machines feel no pain.
NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.
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